BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates to a liquid container regenerating method.
Description of the Related Art
[0002] An ink cartridge for housing ink is one known liquid container that houses a liquid
inside, for example. Also ink cartridges equipped with an ink volume sensor used to
detect the ink volume stored in the ink cartridge are known.
[0003] Various methods are known to charge liquids to a liquid container inside of which
a liquid receptacle is stored, including an ink cartridge inside of which an ink pack
is stored. For example, technology is known by which it is possible to fill liquid
in a liquid container by a step of pressurizing liquid in the liquid container in
the inflow direction and a step of vibrating the liquid.
[0004] However, among such liquid receptacles, there are liquid receptacles equipped with
a liquid volume detector device for detecting the remaining volume or consumed volume
of the liquid stored therein, and when filling liquid in these liquid containers,
there was the risk of problems occurring with the liquid volume detector device, due
to the flow dynamics of the filled liquid, the air bubbles that occur during filling,
and the like.
[0005] Also, after manufacturing, when filling liquid in the liquid container in a state
with the return check valve inside the liquid receptacle functioning, it was not possible
to easily execute because the flow path for filling the liquid was blocked by the
return check valve.
[0006] Furthermore, in the past, when manufacturing ink cartridges equipped with an ink
volume sensor, an ink receptor already filled with ink is connected to the ink volume
sensor. Therefore, when connecting the ink receptor to the ink volume sensor, there
is the risk of ink leakage occurring.
[0007] Another problem is that of having to perform ink filling twice, with ink filling
to the ink receptor and ink filling to the ink volume sensor. Specifically, first,
ink is filled in the ink receptor; and subsequently, after connecting the ink receptor
to the ink volume sensor, ink has to be charged (introduced) into the ink volume sensor
from the ink receptor.
[0008] These problems are not limited to ink cartridges, but rather are problems common
to liquid containers and to liquid containers equipped with liquid receptacles and
liquid volume sensors.
[0009] The present invention is intended to address the problems of the prior art described
above at least in part, and has as one object to reduce the occurrence of problems
with the liquid volume detector device when a liquid container equipped with a liquid
volume detector device is filled with the liquid.
[0010] It is another object of the present invention to easily regenerate a liquid container
for which a liquid receptacle is stored inside.
[0011] It is yet another object of the present invention to reduce liquid leakage during
the process of filling a liquid in the liquid container and to simplify the filling
process.
[0013] US 2007/0188529 A1 relates to a liquid detection device that is accomodated in a sensor accomodating
portion formed in a liquid container containing a liquid therein.
[0014] US 2005/0157109 A1 relates to an ink bag comprising a flexible bag body of a rectangular form and a
folding member attached to one edge of the bag body. This document also relates to
a recycling method of an ink cartridge.
[0015] CN 1 868 751 A relates to an ink cartridge used in an ink jet printer for supplying ink to a print
head, and an ink jet printer using the same.
SUMMARY OF THE INVENTION
[0016] The present application provides a method of regenerating a liquid container. The
method according to the invention comprises the steps of providing the liquid container
having a liquid receptacle capable of housing liquid, and a storage unit which stores
the liquid receptacle and for which the opening is airtight sealed by a sealing member;
separating at least part of the sealing member from the storage unit, removing the
liquid receptacle stored in the storage unit from the opening to outside the storage
unit; storing a liquid receptacle filled with liquid from the opening to the storage
unit; and airtight sealing the opening of the storage unit in which the liquid receptacle
filled with liquid is stored with the sealing member. The method includes machining
a contact surface of the storage unit that contacts the sealing member, and sealing
is executed by adhering the sealing member to the processed contact surface.
[0017] With the method of the invention even when liquid is charged into a used liquid container,
the liquid receptacle is removed from the opening and the liquid receptacle filled
with liquid is stored in the liquid container from the opening, so it is possible
to easily fill liquid in the liquid container. Moreover, in this case, it is possible
to make adhesion of the sealing member and the contact surface of the storage unit
during sealing easy.
[0018] The method of the invention may also include filling liquid in the liquid receptacle;
and the storing may be executed by storing the filled liquid receptacle in the storage
unit. In this case, because storing in the storage unit is done after filling the
liquid in the liquid receptacle, it is possible to easily fill liquid in the liquid
container.
[0019] With the method of the invention the machining may also be executed by smoothing
the contact surface of the storage unit through cutting or grinding. In this case,
by smoothing the part that contacts the sealing member of the storage container, it
is possible to make adhesion of the sealing member easy.
[0020] Sealing may also be executed by heat bonding of the sealing member to the storage
unit. In this case, it is possible to seal the opening by adhering the sealing member
to the storage unit using heat bonding.
[0021] According to the invention, it is possible to execute sealing through ultrasonic
welding of the sealing member to the storage unit. In this case, it is possible to
seal the opening by adhering the sealing member to the storage unit using ultrasonic
welding.
[0022] According to the invention, the sealing maybe executed through vibration bonding
of the sealing member to the storage unit. In this case, it is possible to seal the
opening by adhering the sealing member to the storage unit using vibration bonding.
[0023] With the method of the invention, the sealing maybe executed by adhering the sealing
member to the storage unit using an adhesive. In this case, it is possible to seal
the opening by adhering the sealing member to the storage unit using an adhesive.
[0024] With the method of the invention the storing maybe executed by storing the liquid
receptacle not equipped with a return check valve in the storage unit. In this case,
it is possible to easily fill the liquid because the inflow of the liquid is not blocked
by a return check valve during filling of the liquid to the liquid receptacle.
[0025] With the method according to the invention the liquid container may also be equipped
with a liquid volume detector device capable of detecting the volume of a liquid housed
in the liquid receptacle. In this case, the flow path inside the liquid volume detector
device is not used during regeneration, so it is possible to easily do regenerating
of liquid containers for which a liquid volume detector device is mounted.
[0026] Other aspects and advantages of the present invention will become apparent from the
following detailed description, taken in conjunction with the accompanying drawings,
illustrating by way of example the principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The present invention will be readily understood by the following detailed description
in conjunction with the accompanying drawings. To facilitate this description, like
reference numerals designate like structural elements.
FIG. 1 is an explanatory drawing showing the schematic structure of the ink cartridge
of the first example, not belonging to the invention;
FIG. 2 is an explanatory drawing showing the schematic structure of the cross section
of the ink cartridge of the first example, not being part of the invention;
FIG. 3 is a flow chart showing the procedure of the ink liquid container manufacturing
method of the first example, not being part of the invention;
FIG. 4 is an explanatory drawing showing the state of an ink cartridge with the ink
consumed;
FIG. 5 is an explanatory drawing showing the state with the sensor removed from the
ink cartridge;
FIG. 6 is an explanatory drawing showing the state of ink being filled in the ink
cartridge;
FIG. 7 is an explanatory drawing showing the state with the sensor attached to the
ink cartridge;
FIG. 8 is an explanatory drawing showing the state with ink suctioned from the ink
cartridge;
FIG. 9 is a flow chart showing the procedure of the ink cartridge manufacturing method
of the second example, not being part of the invention;
FIG. 10 is an explanatory drawing showing the state of the ink pack stored in the
storage container;
FIG. 11 is an explanatory drawing showing the schematic structure of a printer using
the ink cartridge;
FIG. 12 is an explanatory drawing showing a variation example of attaching a sensor
to the ink cartridge;
FIG. 13 (A) and FIG. 13 (B) are explanatory drawings showing the schematic structure
of an ink cartridge not being part of the invention;
FIG. 14 is an explanatory drawing showing the schematic structure of the cross section
of an ink cartridge not being part of the invention;
FIG. 15 is a flow chart showing the procedure of the ink liquid container regenerating
method of the invention;
FIG. 16 is an explanatory drawing showing the state of an ink cartridge with the ink
consumed;
FIG. 17 is an explanatory drawing showing the state with the sealing member peeled
from the ink cartridge;
FIG. 18 is an explanatory drawing showing the state with the ink pack removed from
the ink cartridge;
FIG. 19 (A) and FIG. 19 (B) are explanatory drawings showing the state with ink filled
in the ink pack;
FIG. 20 is an explanatory drawing showing the state of the junction surface of the
sealing member and the opening edge;
FIG. 21 is an explanatory drawing showing the state with the ink pack stored in the
ink cartridge;
FIG. 22 (A) through FIG. 22 (C) are explanatory drawings showing the state of the
contact part of the sealing member and the opening edge;
FIG. 23 is an explanatory drawing of removing the ink pack from the ink cartridge
with variation example 1 of the invention;
FIG. 24 is an explanatory drawing of removing the ink pack from the ink cartridge
with variation example 2 of the invention;
FIG. 25 is a plan view typically showing the liquid container used with the fourth
example, not being part of the invention;
FIG. 26 is a side view typically showing the liquid container used with the fourth
example, not part of the invention;
FIG. 27 is a front view typically showing another example of liquid container, bot
being part of the invention;
FIG. 28 is an explanatory drawing showing the junction of the liquid receptacle and
the liquid volume detector used in another example;
FIG. 29 is a plan view typically showing the sensor module of the ink volume sensor
of another example;
FIG. 30 is an explanatory drawing typically showing the cross section of the sensor
module cut at line 5-5 of FIG. 29;
FIG. 31 is a flow chart showing an exemplary ink filling process not being part of
the invention;
FIG. 32 is an explanatory drawing showing the state of the ink cartridge at the start
of the ink filling process;
FIG. 33 is an explanatory drawing showing the state of the ink cartridge midway in
the ink filling process;
FIG. 34 is an explanatory drawing showing the state of the ink cartridge at the end
of the ink filling process;
FIG. 35 is an explanatory drawing typically showing the flow of ink inside the sensor
module when the ink supply pressure is lower than the biasing force;
FIG. 36 is an explanatory drawing typically showing the flow of ink inside the sensor
module when the ink supply pressure is higher than the biasing force;
FIG. 37 is a flow chart showing an ink cartridge manufacturing process not according
to the invention;
FIG. 38 is an explanatory drawing showing an example of the ink lead-out unit equipped
with a return check valve;
FIG. 39 is an explanatory drawing showing the state of the return check valve functioning
with the ink lead-out unit equipped with a return check valve;
FIG. 40 is a schematic structure diagram of the printing device used with an ink cartridge
not being part of the invention; and
FIG. 41 is an explanatory drawing typically showing the internal structure of the
sensor module of another example, not being part of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS.
[0028] Following, the method of regenerating a liquid container according to the present
invention is described based on embodiments while referring to the drawings.
First Example:
[0029] The schematic structure of an ink cartridge that is the liquid container of the first
example not being part of the invention will now be described. FIG. 1 is an explanatory
drawing showing the schematic structure of the ink cartridge. The ink cartridge 10
includes a storage container 20, an ink pack 30, a sensor 40, and a flexible member
50. The ink cartridge 10 of this example contains ink housed in the ink pack 30 constituting
a liquid receptacle supplied to a printer (not illustrated) via the sensor 40 which
is the liquid volume detector device. Note that the liquid container can also be called
a liquid supply body.
[0030] The storage container 20 has a roughly cabinet shape, and is equipped with an opening
24a formed by the opening edge 24 on the top surface. The storage container 20 is
formed from a thermoplastic resin such as polystyrene or the like. The storage container
20 has the ink pack 30 stored in the inside of the container from the opening 24a.
At the side surface of the storage container 20 are provided a pass-through port 21,
a sensor fixing unit 22, and a pressurization port 23. The pass-through port 21 is
engaged with the discharge unit 32 of the ink pack 30 stored in the inside of the
storage container 20, and the ink inside the ink pack 30 can be discharged to outside
the storage container 20. The sensor fixing unit 22 fixes the sensor 40 so as to be
detachable to the outside surface of the storage container 20. The sensor fixing unit
22 can be a member that is engaged using a convex/concave shape, or can be constituted
using a magnet. The pressurization port 23 is able to inflow air to the inside of
the storage container 20.
[0031] The ink pack 30 has a bag 31 and a discharge unit 32. The ink pack 30 houses ink
on the inside of the bag 31, and discharges the housed ink from the discharge unit
32 to outside the ink pack 30. The bag 31 is formed by pasting together the mutual
peripheral edge parts of aluminum laminate multi layer films formed by lamination
of aluminum layers on a resin film layer. The discharge unit 32 has a roughly round
cylinder shape, is connected via the pass-through port 21 to an introduction port
42 that the sensor 40 is equipped with, and leads out the ink housed in the bag 31
to the sensor 40.
[0032] The sensor 40 performs detection of the remaining volume of ink housed in the ink
pack 30. The sensor 40 has a sensor case 40a, a lead-out port 41, an introduction
port 42, and an integrated circuit substrate 43. The sensor 40 introduces ink housed
in the ink pack 30 from the introduction port 42, and leads it out from the lead-out
port 41 connected to the printer via the inside of the sensor case 40a. In this example,
the sensor 40 has a function of detecting the remaining volume of ink inside the ink
pack 30, but the sensor 40 can also be equipped with a function of detecting the consumed
volume of ink consumed by the printer, the flow volume of ink that passes through
the flow path of the sensor 40, or the retained volume of ink housed in the ink receiving
unit. The integrated circuit substrate 43 is electrically connected to a printer (not
illustrated), and provides to the printer the information relating to the residual
volume of ink inside the ink pack 30 detected by the sensor 40.
[0033] The flexible member 50 is a flexible film made of polyethylene terephthalate. The
flexible member 50 is welded to the opening edge 24 of the storage container 20, and
closes the opening 24a. The welding is implemented by fusion using heat of the thermoplastic
resin constituted on the surface that contacts the opening edge 24. The adhesion of
the flexible member 50 and the opening edge 24 can be accomplished not only by heat
bonding, but also by ultrasonic welding, vibration bonding, or using an adhesive.
[0034] FIG. 2 is an explanatory drawing showing the schematic structure of the cross section
of the ink cartridge. Inside the storage container 20 in which the ink pack 30 is
stored is formed a pressurization chamber 25 which is sealed by the flexible member
50 and for which liquid other than that from the pressurization port 23 cannot go
in or out of the inside. By injecting gas inside the pressurization chamber 25 from
the pressurization port 23, the ink pack 30 is compressed, and the ink housed in the
ink pack 30 is discharged.
[0035] The ink pack 30 is equipped with a return check valve 33, a valve seat 34, and packing
35 in the discharge unit 32. The return check valve 33 is a roughly plate shaped valve
having roughly the same shape as the inside cross section of the discharge unit 32.
The return check valve 33 is separated from the valve seat 34 by the flow dynamics
of the ink when discharging the ink housed in the bag 31 to outside the bag 31, and
this makes discharging of the ink possible, but when inflowing ink to the bag 31,
it contacts the valve seat 34 by the flow dynamics in the opposite direction as when
discharging, and functions so as to block the inflow of ink. The packing 35 forms
a ring shape on the inside of the discharge part 32, and when the discharge part 32
is connected to the introduction port 42, by filling in the gaps, outflow of ink from
the connection part to the outside is prevented.
[0036] The sensor case 40a is equipped with a liquid flow path 44, a piezoelectric vibrating
component 45, a liquid detection path 46, a bearing plate 47, a diaphragm 48, and
a spring 49. A flow path in the claims includes the liquid flow path 44 and the liquid
detection path 46. Depending on the volume of ink that flows through the liquid flow
path 44 formed by the diaphragm 48 and the bearing plate 47, the bearing plate 47
rises and falls in resistance to the bias of the spring 49. The free vibration of
the vibrating plate of the piezoelectric vibrating component 45 is permitted or restricted
by the rise and fall operation of the bearing plate 47, and with the back electromotive
force generated in the piezoelectric vibrating component 45 by this free vibration,
signals representing the presence or absence of ink in the printer are output from
the integrated circuit substrate 43.
[0037] The ink cartridge manufacturing method of the first example will now be described.
FIG. 3 is a flow chart showing the process of the ink filling method for the ink cartridge
manufacturing method of the first example. To fill ink in the ink cartridge 10, first,
the ink cartridge 10 for which the ink has been consumed is prepared (step S11). FIG.
4 is an explanatory drawing showing the state of the ink cartridge with the ink consumed.
With the ink cartridge 10, the ink housed in the ink pack 30 is consumed by being
supplied to the printer. The ink inside the ink pack 30 does not have to be completely
consumed.
[0038] After the ink cartridge 10 for which the ink has been consumed is prepared, removal
of the sensor 40 from the ink cartridge 10 is performed (step S12). FIG. 5 is an explanatory
drawing showing the state with the sensor removed from the ink cartridge. Removal
of the sensor 40 can be implemented by releasing the connection between the sensor
fixing unit 22 and the sensor case 40a and by releasing the connection between the
discharge unit 32 and the introduction port 42.
[0039] After the sensor 40 is removed from the ink cartridge 10, filling of the ink into
the ink cartridge 10 is performed (step S13). FIG. 6 is an explanatory drawing showing
the state of ink being filled in the ink cartridge. A filling port 60 is an ink discharge
port provided on the supply device capable of supplying ink to the outside. The shape
of the filling port 60 is roughly the same shape as the introduction port 42 of the
sensor 40. The filling port 60 is connected to the discharge unit 32 of the ink cartridge
10 for which the sensor 40 is removed. Ink is flowed in from the filling port 60 to
the bag 31.
[0040] When charging ink, it is possible to have contact between the return check valve
33 and the valve seat 34 and to block the inflow of ink. However, it is possible to
have the ink flow in to the bag 31 before there is contact by the return check valve
33 with the valve seat 34 by adjusting the pressure of the ink inflow, changing the
installation angle of the discharge unit 32 when filling the ink, or shaking the ink
being filled.
[0041] After the ink is charged into the ink cartridge 10, cleaning of the sensor 40 is
performed (step S14). The sensor 40 has been removed from the ink cartridge 10. The
cleaning of the sensor 40 is implemented by cleaning the liquid flow path 44 and the
liquid detector path 46 that compose the ink flow path. The cleaning can be performed
by inflowing liquid from the introduction port 42 or the lead-out port 41; or a suction
means (suction device) or pressurization means (pressurization device) can be connected
to the introduction port 42 or the lead-out port 41, and the ink remaining in the
liquid flow path 44 and the liquid detection path 46 can be removed using suction
or pressure feed.
[0042] In this example, the sensor 40 is cleaned after the ink is filled into the ink cartridge
10, but as long as it is after the sensor 40 is removed from the ink cartridge 10,
it is also possible to implement cleaning before filling of the ink to the ink cartridge
10 or during filling.
[0043] The sensor 40 after cleaning is attached to the ink cartridge 10 filled with ink
(step S15). FIG. 7 is an explanatory drawing showing the state with the sensor attached
to the ink cartridge. The discharge unit 32 of the ink pack 30 filled with ink and
the introduction port 42 of the sensor 40 for which cleaning is finished are connected
to the bag 31. Also, the sensor case 40a is fixed to the sensor fixing unit 22, and
the sensor 40 is attached to the ink cartridge 10.
[0044] After the sensor 40 is fixed to the ink cartridge 10, suction of the ink from the
ink cartridge 10 is performed (step S16). FIG. 8 is an explanatory drawing showing
the state with ink suctioned from the ink cartridge. A suction device (not illustrated)
is connected to the lead-out port 41 of the ink cartridge 10. By performing suction
using the suction device, the interiors of the liquid flow path 44 and the liquid
detection path 46 are set to negative pressure, and the ink housed in the ink pack
30 is flowed in to the liquid flow path 44 and the liquid detection path 46.
[0045] In addition to the manner of this example for inflow of ink to the liquid flow path
44 an the liquid detection path 46, it is also possible to implement this by injection
of air inside the pressurization chamber 25 using a pressurization means from the
pressurization port 23 and discharging ink from the ink pack 30. It is also possible
to simultaneously implement suction from the lead-out port 41 and the injection of
air from the pressurization port 41.
[0046] The ink that inflows to the liquid flow path 44 and the liquid detection path 46
is heated to a specified temperature to lower the viscosity. Heating of the ink can
be carried out before attachment of the sensor 40 to the storage container 20, and
can also be carried out after attachment, as long as it is before the inflow of ink
to the liquid flow path 44 and the liquid detection path 46.
[0047] The inflow of ink to the liquid flow path 44 and the liquid detection path 46 is
executed until the volume of ink inside the ink pack 30 reaches a specified volume.
When there is inflow of ink at greater than the capacity that can be received inside
the liquid flow path 44 and the liquid detection path 46, the ink is discharged from
the lead-out port 41.
[0048] With the liquid container manufacturing method of the first example described above,
even in a case of charging ink to the ink cartridge 10 equipped with the sensor 40,
the ink is charged with the sensor 40 removed from the ink cartridge 10, so it is
possible to reduce the occurrence of problems with the sensor 40 due to ink filling.
The liquid container manufacturing method of the first example can also be called
a method of filling a liquid (ink) in a liquid container.
[0049] With the liquid container manufacturing method of the first example, because the
ink is filled into the ink pack 30 after the sensor 40 connected to the ink pack 30
is removed, even when filling ink for reuse of the ink cartridge 10, it is possible
to reduce the occurrence of problems with the sensor 40 due to ink filling.
[0050] With the liquid container manufacturing method of the first example, it is possible
to fill ink into the ink cartridge 10 for which the opening 24a for storing the ink
pack 30 in the storage container 20 is closed by the flexible member 50.
[0051] With the liquid container manufacturing method of the first example, it is possible
to eliminate air bubbles inside the liquid flow path 44 and the liquid detection path
46 by inflowing ink housed in the ink pack 30 to the liquid flow path 44 and the liquid
detection path 46 using a suction device. By doing this, it is possible to reduce
the decrease in function of the sensor 40, and it is possible for the ink cartridge
10 to supply ink with stability.
[0052] With the liquid container manufacturing method of the first example, the inflow of
ink to the liquid flow path 44 and the liquid detection path 46 is implemented until
the volume of ink inside the ink pack 30 reaches a specified volume, so it is possible
to maintain the suitability of the volume of liquid received by the ink pack 30, and
in addition to reducing the variation of the ink for each ink pack 30, it is also
possible to implement suitable ink discharge by suppressing the ink within the ink
pack 30 to an allowed holding capacity range.
[0053] With the liquid container manufacturing method of the first example, by cleaning
the liquid flow path 44 and the liquid detection path 46 before attaching the sensor
40 to the storage container 20, it is possible to eliminate air bubbles inside the
liquid flow path 44 and the liquid detection path 46. By doing this, it is possible
to reduce the decrease in function of the sensor 40, and possible for the ink cartridge
10 to supply ink with stability.
[0054] With the liquid container manufacturing method of the first example, the ink flowed
in to the liquid flow path 44 and the liquid detection path 46 is heated to a specified
temperature, the ink viscosity is lowered, and not only is it easier to inflow to
the liquid flow path 44 and the liquid detection path 46, but it is also possible
to reduce the occurrence of air bubbles due to inflow.
Second Example:
[0055] In the first example, a method of manufacturing the ink container (ink cartridge)
for filling ink to reuse the ink cartridge 10 for which the ink has been consumed
is described. Specifically, a case of a manufacturing method (regenerating method)
for reusing the liquid container is explained. As the second example, we will describe
an example of applying this when manufacturing the ink cartridge 10, which is not
part of the invention.
[0056] The schematic structure of the ink cartridge of the second example is the same structure
as the ink cartridge of the first example, so its description is omitted here. Here,
the method of manufacturing the ink cartridge of the second example will be described.
FIG. 9 is a flow chart showing the procedure of the ink cartridge manufacturing method
of the second example. To manufacture the ink cartridge 10, first, the ink pack 30
which is not filled with ink is prepared (step S21). The ink pack 30 can be newly
manufactured, or it can be a used item. In the case of a used item, the ink does not
have to be completely consumed.
[0057] The ink pack 30 is stored in the storage container 20 (step S22). FIG. 10 is an explanatory
drawing showing the state of the ink pack stored in the storage container. To store
the ink pack 30, first, a storage container 20 equipped with an opening 24a is prepared.
The storage container 20 can be newly manufactured or it can be a used item. The prepared
ink pack 30 is introduced inside the storage container 20 from the opening 24a of
the storage container 20, and is engaged with the pass-through port 21 and the discharge
unit 32.
[0058] The opening 24a of the storage container 20 in which the ink pack 30 is stored is
closed using the flexible member 50 (step S23). The flexible member 50 is prepared,
the opening edge 24 is heat welded, and the opening 24a is closed. As long as it is
after the ink pack 30 is stored in the storage container 20, the closing of the opening
24a can be after the ink filling described later or it can be after the attachment
of the sensor 40.
[0059] The ink cartridge 10 is filled with ink (step S24). The same as with embodiment 1,
the filling port 60 is connected to the discharge unit 32, and filling of the ink
into the ink cartridge 10 is performed by inflowing ink to the bag 31. The explanatory
drawing of filling the ink in the ink cartridge 10 is as shown in FIG. 6.
[0060] The sensor 40 is attached to the ink cartridge 10 (step S25). As in the first example,
the discharge unit 32 of the ink pack 30 for which ink is filled in the bag 31 and
the introduction port 42 of the sensor 40 are connected, and the sensor case 40a is
fixed to the sensor fixing unit 22. The explanatory drawing of the attachment of the
sensor 40 to the ink cartridge 10 is as shown in FIG. 7.
[0061] Ink is suctioned from the ink cartridge 10 (step S26). As in the first example, suction
is performed by a suction device (not illustrated) at the lead-out port 41 of the
ink cartridge 10, and the ink housed in the ink pack 30 is flowed in to the liquid
flow path 44 and the liquid detection path 46. The explanatory drawing of ink being
suctioned from the ink cartridge 10 is as shown in FIG. 8.
[0062] With the manufacturing method of the second example described above, even during
manufacturing of the ink cartridge 10 equipped with the sensor 40, the sensor 40 is
attached after the ink is filled in the ink pack 30, so it is possible to manufacture
liquid containers with a reduction in the occurrence of problems with the sensor 40
due to ink filling.
[0063] With the method of manufacturing the ink cartridge of the second example, the ink
pack 30 is stored in the storage container 20, and for the ink cartridge 10 for which
the opening 24a is closed using the flexible member 50, it is possible to manufacture
this with a reduction in the occurrence of problems with the sensor 40.
[0064] With the ink cartridge manufacturing method of the second example, the effects of
inflowing ink housed in the ink pack 30 to the liquid flow path 44 and the liquid
detection path 46, having the ink volume inside the ink pack 30 be a specified volume,
and heating the ink to a specified temperature, are the same as those of the first
example.
[0065] An example of using the ink cartridge 10 obtained using the manufacturing method
of this example will now be described. FIG. 11 is an explanatory drawing showing the
schematic structure of a printer using the ink cartridge. The printer 100 is an inkjet
printer that records text or graphics by spraying ink drops on printing paper P. The
printer 100 is equipped with a paper supply tray 15, a paper ejection tray 16, and
a case 17. The printer 100 introduces printer paper P inside the case 17 from the
paper tray 15, sprays ink drops on a printing mechanism 13 inside the case 17, and
ejects the printing paper P on which text or graphics are recorded from the paper
ejection tray 16 to outside the case 17.
[0066] The case 17 has stored inside it the ink cartridge 10 of this embodiment, an ink
supply unit 11, a supply tube 12, the printing mechanism 13, and a control unit 14.
The ink cartridges 10 house inside them respectively black, cyan, magenta, and yellow
ink. Each color ink cartridge 10 is connected to the ink supply unit 11. It is also
possible to connect four or more colors of ink cartridge 10 to the ink supply unit
11 with a printer that performs printing with four or more colors of ink.
[0067] The ink supply unit 11 has the ink cartridge 10 and the supply tube 12 connected.
The connected ink cartridge 10 receives the supply of ink, and supplies ink to the
printing mechanism 13 via the supply tube 12. The printing mechanism 13 incorporates
a spray head (not illustrated), and is equipped with a carriage (not illustrated)
connected to the supply tube 12. The carriage is moved by a motor (not illustrated),
and spraying of the ink drops on the printing paper P is performed from the spray
head. The control unit 14 controls each part of the printer 100, and also is electrically
connected to the integrated circuit substrate 43 of the ink cartridge 10, and receives
information regarding the remaining volume of ink.
[0068] FIG. 12 is an explanatory drawing showing a variation example of attaching a sensor
to the ink cartridge and is not part of the invention. Here the sensor 40 in a state
for which ink is not filled inside the liquid flow path 44 and the liquid detection
path 46 is connected with the ink pack 30, but it is also possible to add a step of
filling ink inside the liquid flow path 44 and the liquid detection path 46 in advance
before connecting with the ink pack 30, and to connect the sensor 40 filled with ink
to the ink pack 30. Also, when filling ink in the sensor 40, it is also possible to
fill ink that has been heated to a specified temperature.
[0069] In the ink cartridge 10 of this example the opening 24a of the storage container
20 is closed off with the flexible member 50, but it is also possible to use a material
that is not flexible, as long as it is possible to form an airtight pressurization
chamber 25.
[0070] The ink cartridge 10 of this example is equipped with a return check valve at the
discharge unit 32 of the ink pack 30, but it is also possible to constitute the ink
pack 30 without the return check valve.
[0071] In this example, the ink charged to the ink pack 30 was heated and introduced to
the sensor 40, but it is also possible to heat the ink charged to the ink cartridge
10 to a specified temperature in advance and to introduce this to the ink pack 30.
[0072] In the first example, after cleaning the sensor 40 which was removed from the storage
container 20, it was reattached, but it is also possible to attach a different sensor
40 to the storage container 20 than the sensor 40 that was removed.
[0073] With the ink cartridge manufacturing methods according to the variation examples
described above, it is possible to reduce the occurrence of air bubbles inside the
liquid flow path 44 and the liquid detection path 46 by connecting the sensor 40 for
which ink is filled inside the liquid flow path 44 and the liquid detection path 46
to the ink pack 30. By doing this, it is possible to reduce the decrease in functioning
of the sensor 40, and it is possible for the ink cartridge 10 to supply ink with stability.
[0074] Also, if the discharge unit 32 of the ink pack 30 is not equipped with a return check
valve, it is possible to easily fill with ink during filling of the ink to the ink
pack 30 without blocking the inflow of ink by contact by the return check valve 33
with the valve seat 34.
Third Example:
[0075] The schematic structure of the ink cartridge which is the liquid container of the
third example will now be described. FIG. 13 is an explanatory drawing showing the
schematic structure of the ink cartridge. The ink cartridge 10 is equipped with a
cabinet unit 20, the ink pack 30, the liquid volume detector device 40, the sealing
member 50, and a lid 60. With the ink cartridge 10 of this example the ink housed
in the ink pack 30 which is the liquid receptacle is supplied to a printer (not illustrated)
via the liquid volume detector device 40. In the following explanation, the same reference
numbers used in the first or second examples are used.
[0076] As shown in FIG. 13 (A), the cabinet unit 20 has a roughly cabinet shape, and is
equipped with two independent items, an ink receiver 22a and sensor receiver chamber
22b. The top surface of the ink receiving chamber 22a is equipped with the opening
24a formed by the opening edge 24. The cabinet unit 20 is formed by a thermoplastic
resin such as polystyrene or the like. The cabinet unit 20 stores the ink pack 30
in the ink receiving chamber 22a from the opening 24a. As shown in FIG. 13 (B), the
cabinet unit 20 is equipped with a first opening 21a, a second opening 21b, a third
opening 21c, and a fourth opening 21d. The first opening 21a and the fourth opening
21d link the ink receiving chamber 22a and the sensor receiving chamber 22b, and the
second opening 21b and the third opening 21c link the sensor receiving chamber 22b
and outside of the cabinet unit 20. The first opening 21a is used to connect the ink
pack 30 and the liquid volume detector device 40. The second opening 21b is used to
discharge the ink inside the liquid volume detector device 40 to outside the cabinet
unit. The third opening 21c and the fourth opening 21d are used to arrange a pressurization
tube 23 for supplying pressurized air to the ink receiving chamber 22a from outside
the cabinet unit.
[0077] The ink pack 30 is equipped with the bag 31 and the discharge unit 32. The ink pack
30 receives ink inside the bag 31, and the ink received from the discharge unit 32
is discharged to outside the ink pack 30. The bag 31 is formed by pasting together
the peripheral edge parts of the aluminum laminate multi layer film formed by lamination
of aluminum layers on the resin film layer. The discharge unit 32 has a roughly round
cylinder shape, is connected via the first opening 21a to the introduction port 42
that the liquid volume detector device 40 described later is equipped with, and the
ink housed in the bag 31 is led-out to the liquid volume detector device 40.
[0078] The liquid volume detector device 40 performs detection of the remaining volume of
ink housed in the ink pack 30. The liquid volume detector device 40 is equipped with
a sensor case 40a, a lead-out port 41, and an introduction port 42. The liquid volume
detector device 40 introduces the ink housed in the ink pack 30 from the introduction
port 42, and discharges it from the lead-out port 41 connected to the printer via
the inside of the sensor case 40a. In this example, the liquid volume detector device
40 is equipped with a function of detecting the remaining volume of ink inside the
ink pack 30, but in addition, it is also possible to be equipped with a function of
detecting the ink consumption volume consumed by the printer, the flow volume of ink
that posses through the flow path of the liquid volume detector device 40, or the
pooled ink volume housed in the ink receptor. The integrated circuit substrate 43
is fixed to the side surface of the cabinet unit 20 so as to be electrically connected
to the liquid volume detector device 40, and provides information relating to the
remaining volume of ink inside the ink pack 30 detected by the liquid volume detector
device 40 to the printer (not illustrated).
[0079] The sealing member 50 is a flexible film for which one surface is constituted by
a junction material 52 made from the same material as the cabinet unit 20, such as
polystyrene, for example, and the other is constituted by a surface material 51 made
from the polyethylene terephthalate of the backing member. The sealing member 50 is
welded to the opening edge 24 of the cabinet unit 20, and the opening 24a is sealed.
The welding can be implemented through heat fusion of the junction material 52 in
a state facing opposite the surface made from the junction material 52 at the side
of the surface in contact with the opening edge 24. Adhesion of the sealing member
50 and the opening edge 24 can be accomplished not only by heat bonding as taught
in this example but can also be accomplished using ultrasonic welding, vibration bonding,
or adhesion using an adhesive agent.
[0080] FIG. 14 is an explanatory drawing showing the schematic structure of the cross section
of the ink cartridge. The ink receiving chamber 22a in which the ink pack 30 is stored
is made airtight by the sealing member 50, and liquid cannot go out or in other than
from the pressurization tube 23. By injecting gas inside the ink receiving chamber
22a from the pressurization tube 23, the ink pack 30 is compressed, and the ink housed
in the ink pack 30 is discharged.
[0081] The ink pack 30 is equipped with the return check valve 33, the valve seat 34, and
the packing 35 on the discharge unit 32. The return check valve 33 is a roughly plate
shaped valve unit with roughly the same shape as the inside cross section of the discharge
unit 32. The return check valve 33 can separated from the valve seat 34 by the ink
flow dynamics and discharge ink when discharging ink housed in the bag 31 to outside
the bag 31, but when inflowing ink to the bag 31, it functions so as to contact the
valve seat 34 by the flow dynamics in the opposite direction from those during discharging,
which blocks the inflow of ink. The packing 35 forms a ring shape on the inside of
the discharge unit 32, and when the discharge unit 32 connects with the introduction
port 42, by filling in the gap, outflow of ink to outside from the connection part
is prevented.
[0082] The sensor case 40a is equipped with the liquid flow path 44, the piezoelectric vibrating
component 45, the liquid detection path 46, the bearing plate 47, the diaphragm 48,
and the spring 49. The bearing plate 47 rises and falls in resistance to the bias
of the spring 49 according to the volume of ink that flows through the liquid flow
path 44 formed by the diaphragm 48 and the bearing plate 47. By rising and falling
operation of the bearing plate 47, the shape and capacity of the liquid flow path
44 that contacts the vibrating plate of the piezoelectric vibrating component 45 changes,
and the back electromotive force generated at the piezoelectric vibrating component
45 changes. The presence or absence of ink is determined by the printer by outputting
this back electromotive force information to the printer via the integrated circuit
substrate 43.
Method of regenerating a liquid container according to the invention
[0083] The ink cartridge regenerating method according to the invention will now be described.
FIG. 15 is a flow chart showing the process of the ink filling method for the ink
cartridge regenerating method of the invention. To implement filling of ink in the
ink cartridge 10, first, the ink cartridge 10 for which the ink has been consumed
is provided (step S31). FIG. 16 is an explanatory drawing showing the state of the
ink cartridge with the ink consumed. As shown in FIG. 16, for the ink cartridge 10,
an item was provided for which the ink housed in the ink pack 30 is consumed by being
supplied to the printer. The ink inside the ink pack 30 also does not have to be completely
consumed.
[0084] The lid 60 of the provided ink cartridge 10 is removed, and the sealing member 50
is peeled off (step S32). FIG. 17 is an explanatory drawing showing the state with
the sealing member peeled from the ink cartridge. As shown in FIG. 17, after removing
the lid 60, so that it becomes possible to remove the ink pack 30 from the cabinet
unit 20 for which the opening 24a is sealed by the sealing member 50, the welded part
with the opening edge 24 of the sealing member 50 is peeled. The welded part can also
be peeled from the opening edge 24 so as to completely separate the sealing member
50 and the cabinet unit 20.
[0085] After the sealing member 50 is peeled off, the ink pack 30 is removed from the ink
cartridge 10 (step S33). FIG. 18 is an explanatory drawing showing the state with
the ink pack removed from the ink cartridge. As shown in FIG. 18, the removal of the
ink pack 30 can be implemented by releasing the connection of the discharge unit 32
of the ink pack 30 and the introduction port 42, and by removing it to the outside
of the cabinet unit 20 from the opening 24a.
[0086] Filling of ink to the removed ink pack 30 is performed (step S34). FIG. 19 is an
explanatory drawing showing the state with ink filled in the ink pack. When filling
the ink, because the return check valve 33 functions, though it takes time, the pressure
received by the return check valve 33 changes by changing of the injection flow volume
of the charging difference, and it is also possible to fill by applying vibration.
It is also possible to use the ink pack 30 filled with ink by the method shown in
FIG. 19 without using the removed ink pack 30. As shown in FIG. 19 (A), a supply port
70 of a filling device to which ink can be supplied and the ink pack 30 discharge
unit 32 are connected, and the ink is flowed into the bag 31. The ink is flowed into
the bag 31 via a bypass path 32a on the discharge unit 32, so it is possible to fill
ink without blocking of the inflow by the return check valve 33. After the ink is
filled, as shown in FIG. 19 (B), the bypass path 32a is plugged by heat bonding of
the bag 31. In addition to this, it goes without saying that in a case when the ink
pack that is interchanged with the removed ink pack 30 is not equipped with a return
check valve, or with an ink pack equipped with a return check valve that functions
by being attached to the ink cartridge, when using an ink pack that is not a newly
manufactured item, it is possible to do filling easily.
[0087] The opening edge 24 of the cabinet unit 20 is made smooth (step S35). FIG. 20 is
an explanatory drawing showing the state of the junction surface of the sealing member
and the opening edge. As shown in FIG. 20, when peeling the sealing member 50 from
the opening edge 24, part of the junction material 52 is separated from the surface
material 51, and is attached to the opening edge 24. Part of the surface material
51 is also separated and attached to the opening edge 24. Because of this, using a
machining mechanism such as a grinder or the like, the surface of the opening edge
24 is scraped, and the surface material 51 and junction material 52 attached to the
opening edge 24 are removed.
[0088] According to an embodiment of the invention, the smoothing of the opening edge 24
is implemented after removing the ink pack 30 from the cabinet unit 20, but as long
as it is after the sealing member 50 is peeled from the ink cartridge 10, it can also
be implemented before removing the ink pack 30 from the ink cartridge 10. It is also
possible to implement this after storing the ink pack 30 described later in the cabinet
unit 20.
[0089] After the opening edge 24 is smoothed, the ink pack 30 is stored in the ink cartridge
10 (step S36). FIG. 21 is an explanatory drawing showing the state with the ink pack
stored in the ink cartridge. As shown in FIG. 21, the ink pack 30 filled with ink
is arranged inside the cabinet unit 20 from the opening 24a, and this is stored in
the ink cartridge 10 by the discharge 32 being connected with the introduction port
42.
[0090] The sealing member 50 is welded to the ink cartridge 10 in which the ink pack 30
is stored (step S37). FIG. 22 is an explanatory drawing showing the state of the contact
part of the sealing member and the opening edge. As shown in the embodiment of the
invention of FIG. 22 (A), the junction material 52 that the sealing member 50 is equipped
with and the opening edge 24 are in contact, and this is welded to the opening edge
24 by fusing the junction material 52 using heat. By doing this, the sealing member
50 seals the opening 24a.
[0091] In addition to the heat bonding of this embodiment for the welding of the sealing
member 50 and the opening edge 24, it is also possible to repeatedly add compression
force to the sealing member 50, to do ultrasonic welding that adheres by heat generation
inside the member, or to use vibration bonding that adheres by heat using friction.
In this case, as shown in FIG. 22 (B), a convex part 24b is formed on the opening
edge 24, and welding can be done by fusing the convex part 24b using heat. Also, as
shown in FIG. 22 (C), it is also possible for the sealing member 50 to be equipped
with a convex part. By welding of the sealing member 50, regeneration of the ink cartridge
according to the invention is completed.
[0092] With the ink cartridge regenerating method according to the invention, even when
filling ink in the used ink cartridge 10, the ink pack 30 is removed from the opening
24a, so it is possible to fill ink in the ink pack 30 without using the flow path
inside the liquid volume detector device. Also, to store the ink pack 30 filled with
ink in the ink cartridge 10, while reducing the possibility of problems occurring
in the liquid volume detector device due to filling, it is possible to easily fill
the ink cartridge 10 with ink.
[0093] With the ink cartridge regenerating method of the invention, the surface of the opening
edge 24 is machined before welding the sealing member 50 to the cabinet unit 20, so
it is possible to remove the junction material 52 and the like adhered to the opening
edge 24, and it is possible to easily weld the sealing member 50.
[0094] With the ink cartridge regenerating method of the invention, storing in the cabinet
unit 20 is done after filling of the ink in the ink pack 30, so, for example, with
a new ink pack, it is possible to fill the ink using a method called a bypass path
that does not go via the return check valve, and it is possible to easily fill ink
in the ink cartridge 10.
[0095] With the ink cartridge regenerating method according to the invention, the sealing
member 50 and the opening edge 24 are welded using heat bonding, ultrasonic welding,
or vibration bonding. By doing this, because the inside of the ink receiving chamber
22a is airtight sealed, it is possible for the ink cartridge 10 to supply ink with
stability.
[0096] With the ink cartridge regenerating method according to the invention, the ink cartridge
10 is equipped with a liquid volume detector device 40, so it is possible to fill
ink even in the ink cartridge 10 equipped with the liquid volume detector device 40.
Example of Use of the Ink Cartridge regenerated according to the invention:
[0097] An example of using the ink cartridge 10 regenerated by the ink cartridge regenerating
method of the invention will now be described. FIG. 11 is an explanatory drawing showing
the schematic structure of the printer using the ink cartridge. The printer 100 is
an inkjet printer for recording text or graphics by spraying ink drops on the printing
paper P. The printer 100 is equipped with the paper supply tray 15, the paper ejection
tray 16, and the case 17. The printer 100 introduces the printing paper P from the
paper supply tray 15 to inside the case 17, sprays ink drops with the printing mechanism
13 inside the case 17, and discharges the printing paper P on which text or graphics
are recorded from the paper ejection tray 16 to outside the case 17.
[0098] The case 17 is constituted from the lid and the main body, and inside it are stored
the ink cartridge 10 of this embodiment, the ink supply unit 11, the supply tube 12,
the printing mechanism 13, and the control unit 14.
[0099] The ink cartridge 10 receives ink of different colors for each ink cartridge inside
it. With this embodiment, each ink cartridge 10 receiving black, cyan, magenta, and
yellow ink is connected to the ink supply unit 11. As another example, with a printer
that performs printing with four or more colors of ink, it is also possible to connect
four or more colors of ink cartridges 10 to the ink supply unit 11.
[0100] The ink supply unit 11 has the ink cartridge 10 and the supply tube 12 connected.
The supply of ink is received from the connected ink cartridge 10, and ink is supplied
via the supply tube 12 to the printing mechanism 13. The supply tube 12 is formed
with a material having gas permeability, for example, a thermoplastic elastomer such
as an olefin, a styrene or the like.
[0101] The printing mechanism 13 incorporates a spray head (not illustrated), and is equipped
with a carriage (not illustrated) connected to the supply tube 12. The carriage is
moved by a motor (not illustrated), and spraying of ink drops on the printing paper
P is performed from the spray head.
[0102] The control unit 14 controls each part of the printer 100 . The control unit 14 an
includes ASIC (Application Specific Integrated Circuit) equipped with hardware such
as a central processing unit (CPU) (not shown), a read only memory (ROM), and random
access memory (RAM) and the like. Software for realizing the various functions of
the printer 100 is installed in the control unit 14. It is also electrically connected
with the integrated circuit substrate 43 and receives information regarding the remaining
volume of ink.
Modified Embodiments:
[0103] It is to be understood that the present invention can be embodied in various other
modes without departing from the scope of the appended claims.
Modified Embodiment 1:
[0104] FIG. 23 is an explanatory drawing of removing the ink pack from the ink cartridge
with variation example 1. With this embodiment, the sealing member 50 is separated
from the opening edge 24 and the ink pack 30 is removed from the opening 24a, but
it is also possible to provide a sealing member opening 50a at part of the sealing
member 50 to remove the ink pack 30.
Modified Embodiment 2:
[0105] FIG. 24 is an explanatory drawing of removing the ink pack from the ink cartridge
with variation example 2. With this embodiment, the sealing member 50 is separated
from the opening edge 24 and the ink pack 30 is removed from the opening 24a, but
it is also possible to remove the ink pack 30 by cutting the cabinet unit 20 near
the opening edge 24. In this case, for the sealing of the opening 24a, the sealing
member 50 is welded to the generated surface 24c newly created by cutting.
Modified Embodiment 3:
[0106] The ink cartridge 10 of this embodiment has adhesion of the sealing member 50 and
the opening edge 24 implemented by welding, but as long as the opening 24a is airtight
sealed, adhesion can be done using an adhesive agent or the like.
Fourth Example
[0107] With the fourth example, we will describe the method of filling liquid to the liquid
container, not being part of the present invention.
[0108] FIG. 25 is a plan view typically showing the liquid container used in this example.
FIG. 26 is a side view typically showing the liquid container used with this example.
FIG. 27 is a front view typically showing the liquid container used with this example.
FIG. 28 is an explanatory drawing showing the junction of the liquid receptacle and
the liquid volume detector used in this example.
[0109] As an example of the liquid container, an ink cartridge used mounted on an inkjet
printer is used. The ink cartridge 110 is equipped with the case 120, the lid 125,
the ink receptor 130, and the ink volume sensor 140. Note that with FIG. 25, for purposes
of explanation, this will described using the ink cartridge 110 which is not equipped
with the lid 125. Also, the ink receptor 130 correlates to the liquid receptacle and
the ink volume sensor 140 correlates to the liquid volume detector.
[0110] The case 120 has an external appearance forming a roughly rectangular solid shape
and has two independent items, an ink receiving chamber 120a and sensor receiving
chamber 120b. Each receiving chamber 120a and 120b has segments formed by a wall surface
120c, and the top surface is open. The case 120 is formed, for example, by a resin
material including a thermoplastic resin, a metal material, or a hybrid material of
metal and resin.
[0111] The case 120 is equipped with the first opening 121a, the second opening 121b, the
third opening 121c, and the fourth opening 121d. The first opening 121a and the fourth
opening 121d link the ink receiving chamber 120a and the sensor receiving chamber
120b, and the second opening 121b and the third opening 121c link the sensor receiving
chamber 120b and the case exterior.
[0112] The first opening 121a is used to connect the ink receptor 130 and the ink volume
sensor 140. The second opening 121b is used to arrange the ink supply port 122. The
third opening 121c and the fourth opening 121d are used to arrange the pressurization
tube 123 for supplying pressurized air to the ink receiving chamber 120a from the
case exterior.
[0113] The lid 125 has a shape corresponding to the top surface shape of the case 120. As
shown in FIG. 26 and FIG. 27, each opening of the case 120 is airtight sealed by the
sealing material 150, and the lid 125 is mounted on the case 120 overlapping the sealing
material 150. The sealing material 150 seals the openings of each receiving chamber
120a and 120b to airtight seal at least the ink receiving chamber 120a. When the ink
cartridge 110 is mounted in the printing device, pressurized air is supplied to the
ink receiving chamber 120a via the pressurization tube 123 from the printing device.
This pressurization process is executed to smooth the supply of ink to the printing
device by adding pressure from the outside to the ink receptor 130. Therefore, the
ink receiving chamber 120a is required to be airtight sealed. As the sealing material
150, it would be possible to use for example a laminate film composed of the same
material as the case 120, e.g. polyethylene terephthalate with a polystyrene backing.
The sealing material 150 is adhered in a state with the surface of the same material
as the case 120 used as the wall surface side of the case 120.
[0114] The ink receptor 130 is equipped with a bag shaped main body and the ink lead-out
unit 131 mounted at one edge of the main body. The main body is formed from a multi
layer film of a rectangular shape for which a gas barrier layer is formed by lamination
on the resin film layer, for example. The ink lead-out unit 131 is formed by a round
cylinder shaped resin member that can be heat bonded with the resin film layer. The
ink receptor 130 is formed by sandwiching the ink lead-out unit 131 between one side
of two multi layer films that are overlapped, and with this example one side among
the short sides, and by heat bonding the film edge part and the film and the ink lead-out
unit 131. As the resin film layer, for example, a thermoplastic resin that can be
heat bonded, such as polyethylene or propylene can be used, as the gas barrier layer,
aluminum can be used, and as the backing member, polyamide or polyethylene terephthalate
can be used.
[0115] The ink volume sensor 140 is equipped with a sensor module unit described later,
a first connecting unit 140a, and a second connecting unit 140b. The first connecting
unit 140a is mounted on the ink lead-out unit 131 of the ink receptor 130 via the
first opening 121a. In specific terms, as shown in FIG. 28, the tip of the first connecting
unit is inserted through the first connecting unit 140a until it reaches the receiving
part inside the ink lead-out unit 131. The outer periphery surface of the first connecting
unit 140a and the inner periphery surface of the ink lead-out unit 131 are sealed
by the sealing member.
[0116] The ink supply port 122 is mounted on the second connecting unit 140b via the second
opening 121b. Note that the ink supply port 122 can be formed as an integrated unit
with the second connecting unit 140b. In this case, the second connecting unit 140b
that functions as the ink supply port projects from the second opening 121b.
Ink Volume Sensor Constitution:
[0117] FIG. 29 is a plan view typically showing the sensor module of the ink volume sensor
of this example. FIG. 30 is an explanatory drawing typically showing the cross section
of the sensor module cut at line 5-5 of FIG. 29.
[0118] The ink volume sensor 140 is equipped with the first connecting unit 140a and the
second connecting unit 140b on the case 40C as described previously. Note that for
purposes of explanation, FIG. 29 shows the state with the top surface of the case
40C of the ink volume sensor 140 removed.
[0119] The ink volume sensor 140 is equipped with the sensor module 141, a first linking
path 142a, and a second linking path 142b. The first linking path 142a links the sensor
module 141 and the first connecting unit 140a, and the second linking path 142b links
the sensor module 141 and the second connecting unit 140b.
[0120] The sensor module 141 is equipped with a sensor case 1411, a pressure receiving body
1412, a diaphragm 1413, a biasing member 1414, a detection flow path forming member
1415, and a sensor 143. The sensor case 1411 planar view makes a circular ring shape,
and is equipped with a top side case member 1411a and a bottom side case member 1411b
for which the circular ring widths differ. Here, With this embodiment, the circular
ring width of the bottom side case member 1411b is larger than the circular ring width
of the top side case member 1411a. As shown in FIG. 30, at the connecting part of
the first linking path 142a and the second linking path 142b of the sensor case 1411,
the linking unit 1411c and 1411d for linking the outside of the sensor case 1411 and
the inside of the sensor case 1411 are respectively formed.
[0121] The detection flow path forming member 1415 has two flow paths inside, and is fixed
to the bottom side case member 1411b by the circular ring fixing member 1416. A detection
flow path 162 is formed by the two flow paths of the detection flow path forming member
1415 and the

shaped sensor 143. The sensor 143 can be constituted from a vibrating plate that
directly contacts the fluid and the sensor main body, or it can be constituted from
only the sensor main body. As the sensor main body, an electrostriction component
which is a passive component that is deformed (electrostriction) by the application
of voltage and that outputs voltage (back electromotive force) according to outside
force is used. As the electrostriction component (piezoelectric element), for example,
it is possible to use zircon lead titanate (PZT), lead lanthanum zirconate titanate
(PZTL), or a lead-free piezoelectric film that does not use lead. The detection signals
generated by the sensor 143 are sent to a control circuit (not illustrated).
[0122] The pressure receiving body 1412 is equipped with a bottom side part having a size
that can close the detection flow path 162, and a top side part of a size that can
be in contact with the biasing member 1414. The pressure receiving body 1412 is connected
to the top side case member 1411a by the diaphragm 1413.
[0123] An ink flow path 161 is formed on the sensor case 1411. When the pressure receiving
body 1412 is in contact with the detection flow path forming member 1415 by the biasing
force of the biasing member 1414, the ink flows through the ink flow path 161. Meanwhile,
when the pressure receiving body 1412 and the detection flow path forming member 1415
are divided, the ink flows through the two flow paths of the ink flow path 161 and
the detection flow path 162.
[0124] The biasing force applied to the pressure receiving body 1412 by the biasing member
1414 can be set, for example, to be weaker than the pressurization force applied to
the ink receptor 130 by the pressurized air during use. As a result, during use, the
pressure receiving body 1412 and the detection flow path forming member 1415 are divided,
and when not used (when removed, when non-pressurized), the pressure receiving body
1412 and the detection flow path forming member 1415 are in contact, and mixing or
the like of air bubbles in the detection flow path 162 is suppressed and prevented.
[0125] We will give a brief description of the ink volume detection using the sensor module
141. The sensor 143 has the role of both an exciter that gives excitation oscillation
to an oscillation system, and an oscillation detector that detects the oscillation
frequency for an oscillation system. In specific terms, the sensor 143 starts excitation
oscillation by stopping the application of drive signals after electrostriction by
application of square wave drive signals. By matching the excitation oscillation count
given to the oscillation system by the sensor 143, specifically, the frequency of
the drive signals applied to the sensor 143, to the oscillation count inherent to
the oscillation system of the sensor module 141, resonance occurs in the oscillation
system. The sensor 143 varies according to the generated resonant oscillation, specifically,
the oscillation is detected, and the voltage value that varies according to the detected
oscillation, specifically, the resonance frequency signals, are output as the detection
result signals.
[0126] The oscillation system of the sensor module 141 indicates a different inherent oscillation
count according to whether or not the detection flow path 162 is plugged by the pressure
receiving body 1412. Pressurization force acts on the ink receptor 130, and when there
is a larger amount of ink than the specified volume in the ink receptor 130, the pressure
receiving body 1412 and the detection flow path forming member 1415 are divided by
high ink pressure, and when there is a smaller amount of ink than the specified volume
in the ink receptor 130, the pressure receiving body 1412 and the detection flow path
forming member 1415 are in contact by the drop in ink pressure. Therefore, the detection
flow path 162 is linked with the ink flow path 161 when there is a larger volume of
ink than the specified volume in the ink receptor 130, and is separated from the ink
flow path 161 when there is ink of the specified volume or less in the ink receptor
130. Specifically, by using the difference in the back electromotive force brought
by the difference in the inherent oscillation count for the oscillation system formed
when the detection flow path 162 is plugged by the pressure receiving body 1412 and
for the oscillation system formed when not plugged, it is possible to judge whether
or not the ink volume received in the ink receptor 130 is the specified volume or
less. Note that the ink volume sensor 140 performs detection of the ink volume based
on changes in ink pressure, so it can be called a pressure sensor.
[0127] The ink volume sensor 140 of this example is a sensor that judges whether or not
the ink volume in the ink receptor 130 is a specified volume or greater as described
above (whether it is less than a specified volume), but in addition to this, for example,
it goes without saying that it is also possible to use a sensor that can detect the
consumed volume or the remaining volume by detecting the total volume (flow volume)
of ink supplied to the printer.
[0128] The method of filling ink in the ink cartridge 110 of this example will now be described.
FIG. 31 is a flow chart showing the ink filling process of this example. FIG. 32 is
an explanatory drawing showing the state of the ink cartridge at the start of the
ink filling process. FIG. 33 is an explanatory drawing showing the state of the ink
cartridge midway in the ink filling process. FIG. 34 is an explanatory drawing showing
the state of the ink cartridge at the end of the ink filling process.
[0129] The ink supply device used with the following process is equipped with an ink reservoir
tank 1200, a first control valve 1201, a second control valve 1202, and an ink supply
pump PP. During ink supply, the first control valve 1201 is in a linked state (open),
and the second control valve 1202 is in an unlinked state (closed), and during the
air removal process, the first control valve 1201 is in an unlinked state (closed),
and the second control valve 1202 is in a linked state (open). Note that in FIG. 32
to 10, the open control valve is white, and the closed control valve is black.
[0130] The ink supply port 122 and the ink supply device for the ink cartridge 110 are connected
(step S100: see FIG. 32). In specific terms, the ink supply port 122 of the ink cartridge
110 in a state with the ink receptor 130 and the ink volume sensor 140 incorporated
is connected to the supply tube that is connected to the discharge port of the ink
supply pump PP. The ink cartridge 110 can be a newly manufactured ink cartridge, or
it can be an ink cartridge that was used once and is refilled with ink for reuse.
In the case of a new ink cartridge, there is no ink in the internal flow paths of
the ink receptor 130 and the ink volume sensor 140. On the other hand, in the case
of a used ink cartridge, when cleaning has not been executed on the ink receptor 130
and the ink volume sensor 140, there is ink in the internal flow paths of the ink
receptor 130 and the ink volume sensor 140.
[0131] The ink supply pump PP is operated with the first control valve 1201 in a linked
state, and the second control valve 1202 in a non-linked state, and filling of ink
to the ink receptor 130 via the ink volume sensor 140 starts (step S110: see FIG.
33). The ink supplied via the ink supply port 122 flows to the ink receptor 130 via
the internal flow paths of the ink volume sensor 140, specifically, at least the first
linking path 142a, the second linking path 142b, and the ink flow path 161.
[0132] Note that when a return check valve is equipped in the ink receptor 130 to prevent
or suppress the reverse inflow of ink from the outside, for example when equipped
in the ink lead-out unit 131, a contrivance is required for the filling of ink. For
example, filling of ink is performed by supply pressure that is less than the operating
pressure of the return check valve, an operating unit is provided on the ink receptor
130 for turning off the return check valve function from the outside, and during ink
filling, the return check valve function is turned off. Alternatively, it is possible
to have at least two flow paths formed on the ink lead-out unit 131 of the ink receptor
130 that link with the ink receptor 130, and to provide a switching valve for switching
the two flow paths. A return check valve can be provided on one flow path, and during
normal use, the flow path equipped with the return check valve is operated, and during
ink filling, the other flow path that is not equipped with a return check valve is
operated.
[0133] Meanwhile, when the return check valve is not equipped in the ink receptor 130, ink
can be filled inside the ink receptor 130 simply by operating the ink supply pump
PP.
[0134] When a specified volume of ink is filled in the ink receptor 130, the ink supply
pump PP is stopped, and the filling of ink to the ink receptor 130 stops (step S120).
[0135] When the ink filling ends, the first control valve 1201 is in a non-linked state,
and the second control valve 1202 is in a linked state, the ink supply pump PP is
put to reverse operation, and the air removal process is executed (step S130: see
FIG. 34). Here, the air removal process is not a required process, but by executing
the air removal process together, it is possible to improve the reliability of eliminating
mixing of air bubbles in the sensor module 141, particularly the detection flow path
162. In specific terms, the pressure receiving body 1412 with the sensor module 141
is divided from the detection flow path forming member 1415, and the suction process
is executed by the pressure that brings the inflow of ink to the detection flow path
162. As a result, the air bubbles inside the detection flow path 162 are discharged
to outside the ink cartridge 110. Also, at the same time, the air bubbles inside the
ink volume sensor 140 and the ink receptor 130 are also discharged to outside the
ink cartridge 110. As a result, it is possible to suppress or stop the generation
of ink volume detection errors due to air bubble mixing.
[0136] When the air removal process is completed, the connection between the ink cartridge
110 ink supply port 122 and the ink supply device is released (step S104). Specifically,
the supply tube is removed from the ink supply port 122.
[0137] Note that the following two modes are conceivable during filling of ink to the ink
cartridge 110. FIG. 35 is an explanatory drawing typically showing the flow of ink
inside the sensor module when the ink supply pressure is lower than the biasing force.
FIG. 36 is an explanatory drawing typically showing the flow of ink inside the sensor
module when the ink supply pressure is higher than the biasing force.
[0138] When the ink supply pressure is lower than the biasing force, as shown in FIG. 35,
the pressure receiving body 1412 and the detection flow path forming member 1415 are
left in contact, and without the inflow port to the detection flow path 162 being
exposed, the ink flows to the ink receptor 130 exclusively through the ink flow path
161. Therefore, by the air removal process described previously, while there is a
requirement for introduction of ink to the detection flow path 162, the detection
flow path 162 is plugged by the pressure receiving body 1412, so there is little mixing
of air bubbles into the detection flow path 162, and it is possible to reduce the
residual air bubbles inside the ink flow path 161.
[0139] Meanwhile, when the ink supply pressure is higher than the biasing force, as shown
in FIG. 36, the pressure receiving body 1412 and the detection flow path forming member
1415 are divided. Therefore, the inflow port to the detection flow path 162 is exposed,
and the ink flows to the ink receptor 130 through the detection flow path 162 and
the ink flow path 161. In this case, by the air removal process described previously,
discharging of the air bubbles mixed in the ink introduced inside the detection flow
path 162 is induced. It is also possible to shorten the time required for the ink
filling process.
[0140] Note that with this example, the sensor module 141 is filled with ink during the
ink filling process, so the air removal process for introducing ink to the sensor
module of the prior art is unnecessary, and the air removal process noted above should
be distinguished from the prior art air removal process for filling ink to the sensor
module.
[0141] As described above, with the ink filling method of the fourth example, the ink filling
is executed in a state with the ink receptor 130 and the ink volume sensor 140 mounted
on the case 120, so it is possible to prevent or suppress ink leakage. Specifically,
the ink filling process is executed with the ink receptor 130 and the ink volume sensor
140 connected, so it is possible to prevent or suppress the ink leakage when connecting
the ink sensor to an ink receptor filled with ink that occurred with the prior art.
As a result, the work of removing the leaked ink and the like during filling of ink
to the ink cartridge is unnecessary, and it is possible to make the ink filling process
more efficient.
[0142] Also, the ink filling process is executed in a state with the ink receptor 130 and
the ink volume sensor 140 connected, so the ink volume sensor 140 interior is filled
with ink during the filling process. Therefore, it is possible to not execute the
ink filling process to the ink volume sensor that was performed with the prior art
in addition to the ink filling process to the ink receptor. As a result, it is possible
to make the ink filling process simpler.
[0143] Furthermore, when filling ink in the ink cartridge 110 that has been used, in addition
to what is noted above, it is also possible to enjoy the advantage that it is possible
to execute refilling of ink to the ink receptor 130 without disassembling the used
ink cartridge 110.
Fifth Example
[0144] The method of manufacturing the ink cartridge of the fifth example, not belonging
to the invention, will be described following. FIG. 37 is a flow chart showing the
ink cartridge manufacturing process of this example. With this example, filling of
the ink to the assembled ink cartridge is executed, so first, assembly of the ink
cartridge is executed (step S200). In specific terms, the ink receptor 130 and the
ink volume sensor 140 are incorporated in the case 120, and the opening of the ink
receiving chamber 120a and the sensor receiving chamber 120b was plugged using the
sealing material 150. First, the ink receptor 130 is arranged in the ink receiving
chamber 130a, and subsequently, the first connecting unit 140a of the ink volume sensor
140 is arranged in the sensor receiving chamber 120b of the ink volume sensor 140
while being inserted in the ink lead-out unit 131 of the ink receptor 130. Insertion
of the first connecting unit 140a into the ink lead-out unit 131 can be executed by
simply pushing in the first connecting unit 140a, or it can be executed by inserting
the first connecting unit 140a while rotating, and making it such that the first connecting
unit 140a and the ink lead-out unit 131 or the wall surface 120c mechanically lock.
[0145] A tube shaped member that becomes the ink supply port 122 is mounted on the second
connecting part 140b of the ink sensor 140 received in the sensor receiving chamber
120b. Also, the pressurization tube 123 (normally formed as an integrated unit with
the case 120) is mounted on the third opening 121c and the fourth opening 121d of
the case 120. Subsequently, the sealing material 150 is arranged in the opening of
the case 120, and the sealing material 150 and the case 120 (end surface of the wall
surface 120c) are adhered using heat bonding, ultrasonic welding or the like. Finally,
the lid 125 is mounted on the case 120 and the assembly of the ink cartridge 110 is
ended. Note that the mounting of the lid 125 can also be executed after completion
of the ink filling process.
[0146] When the ink cartridge 110 is completed, the ink filling process (steps S210 to S250)
corresponding to the previously described ink filling process (steps S100 to S130)
is executed. Specifically, to describe this briefly, the ink supply device is connected
to the ink supply port 122 of the ink cartridge 110 (step S210), and the filling of
ink to the ink receptor 130 is started (step S220). When filling of a specified volume
of ink is completed, the ink filling process is stopped (step S230), the air removal
process is executed (step S240), the connection between the ink cartridge 110 ink
supply port 122 and the ink supply device is released (step S250), and the ink cartridge
110 manufacturing process is completed.
[0147] Note that with the ink cartridge 110 manufacturing process, it is possible to execute
ink filling using a high supply pressure with the method described below even for
the ink receptor 130 equipped with the return check valve. FIG. 38 is an explanatory
drawing showing an example of the ink lead-out unit equipped with a return check valve.
FIG. 39 is an explanatory drawing showing the state of the return check valve functioning
with the ink lead-out unit equipped with a return check valve.
[0148] With the example shown in FIG. 38, the ink lead-out unit 131 is equipped with the
film material 1311 that forms the bag of the ink receptor 130, the return check valve
1312, and the bypass path 1313. During ink filling, the bypass path 1313 and the interior
of the ink receptor 130 are linked, so the ink supplied to the ink lead-out unit 131
flows to the inside of the ink receptor 130 via the bypass path 1313 though it cannot
pass through the return check valve 1312. At the point that filling of the ink to
the ink receptor 130 is completed, as shown in FIG. 39, if the bypass path 1313 is
sealed by the film material 1311, the only path for the ink receptor 130 is the path
via the return check valve 1312. As a result, the return check valve 1312 switches
to the functioning state. Note that the sealing of the bypass path 1313 by the film
material 1311 can be executed by heat bonding, for example.
[0149] When using this mode, the welding of the sealing material 150 to the case 120 is
executed after filling of the ink to the ink receptor 130 has ended and the sealing
of the bypass path 1313 is completed.
[0150] As described above, with the ink cartridge manufacturing method of this example,
filling of the ink is executed in a state with the ink receptor 130 and the ink volume
sensor 140 mounted on the case 120, so it is possible to prevent or suppress ink leakage
during ink cartridge manufacturing. As a result, it is possible to prevent or suppress
dirtying of the ink cartridge due to ink leakage, and the work step of removing leaked
ink or the like is unnecessary, so it is possible to make the manufacturing process
more efficient.
[0151] Also, the ink filling process is executed in a state with the ink receptor 130 and
the ink volume sensor 140 connected, so the inside of the ink volume sensor 140 is
filled with ink during the filling process. Therefore, it is possible to not execute
the ink filling process to the ink volume sensor that was performed with the prior
art in addition to the ink filling process to the ink receptor. As a result, it is
possible to simplify the ink cartridge manufacturing process.
Ink Cartridge Application Example:
[0152] As an application example of the ink cartridge 110 manufactured using the ink cartridge
manufacturing method of the previous example, we will briefly describe this using
an example of the ink cartridge 110 incorporated in a printing device. FIG. 40 is
a schematic structure diagram of the printing device used with an ink cartridge of
this example mounted.
[0153] The printing device 1300 is equipped with a main scan feed mechanism, a sub scan
feed mechanism, a printing head drive mechanism, and a control circuit 1310 for controlling
the drive of each of these mechanisms as well as for executing the various program
functions for controlling the consumption volume of ink as the liquid.
[0154] The main scan feed mechanism is equipped with a carriage motor 1302 for driving the
carriage 1301, a sliding axis 1304 for slidably holding the carriage 1301 installed
in parallel with the axis of the platen 1303, a pulley 1306 for which an endless drive
belt 1305 is extended between it and the carriage motor 1302, and a position sensor
(not illustrated) for detecting the origin point position of the carriage 1301. The
main scan feed mechanism moves the carriage 1301 back and forth in the axis direction
(main scan direction) of the platen 1303 using the carriage motor 1302.
[0155] The carriage 1301 is equipped with printing heads IH1 to IH4. Ink is supplied to
the printing heads IH1 to IH4 from a plurality of ink cartridges 110a to 110d arranged
at different positions from the printing heads IH1 to IH4. Specifically, the printing
device 1300 is an off-carriage type printing device. Note that for the ink cartridge
110, it goes without saying that instead of an off-carriage type, it is also possible
to mount on the printing device an on-carriage type for which the ink cartridge is
mounted on a holder equipped on the printing head.
[0156] Pressurized air of a specified pressure is supplied from a compressor 1400 to the
ink cartridges 110a to 110d. Specifically, by having the pressure inside the ink receptor
130a be a specified pressure via the pressurization tube 123, a specified pressure
is applied to the ink receptor 130 and the supplying of the ink is stabilized.
[0157] The sub scan feed mechanism is equipped with a paper feed motor 1307, and a gear
train 1308. The sub scan feed mechanism conveys the printing paper P in the sub scan
direction by transmitting the rotation of the paper feed motor 1307 to the platen
1303 via the gear train 1308.
[0158] The head driving mechanism drives the printing heads IH1 to IH4 incorporated in the
carriage 1301, controls the ink discharge volume and timing, and forms the desired
dot patterns on the printing medium. As the ink driving mechanism, for example, it
is possible to use a drive mechanism using piezoelectric deformation for which distortion
occurs due to voltage application, or a drive mechanism that uses air bubbles that
occur inside the ink using a heater heated by the application of voltage.
[0159] The control circuit 1310 is connected to the carriage motor 1302, the paper feed
motor 1307, and the operating panel 1309 via a signal line. The control circuit 1310
also can be connected to a computer or a digital still camera via input/output terminals.
The control circuit 1310 drives the carriage motor 1302, the paper feed motor 1307,
and the printing heads IH1 to IH4 according to instructions from the computer and
the operating panel 1309, or according to various programs stored in the control circuit
1310.
Alternative Embodiments/Examples:
[0160]
- (1) It is also possible to equip a pressure receiving body flow path 163 that is linked
with the detection flow path 162 and the ink flow path 161 on the pressure receiving
body 1412 that constitutes the sensor module 141. FIG. 41 is an explanatory drawing
typically showing the internal structure of the sensor module of another example.
By forming the pressure receiving body flow path 163 on the pressure receiving body
1412, it is possible to make introduction of ink to the detection flow path 162 easier.
Specifically, by equipping the pressure receiving body flow path 163 parallel to the
ink flow direction during the ink filling process, even in a state when the pressure
receiving body 1412 and the detection flow path forming member 1415 are not sufficiently
divided, it is possible to effectively introduce ink to the detection flow path 162.
It is also possible to make introduction of the ink to the detection flow path 162
more efficient by adjusting the distance between the pressure receiving body flow
path 163 and the linking unit 1411c.
- (2) With each of the examples noted above, the lid 125 was used, but it is also possible
to not use the lid 125. Specifically, this is because though the lid 125 exhibits
the function of stopping damage to the sealing material 150, the ink receiving chamber
130a and the sensor receiving chamber 130b are sealed by the sealing material 150,
and it is possible to execute pressurization processing on the ink receiving chamber
130a. Also, by using a flexible, thin plate member as the sealing material 150, the
lid 125 is no longer an essential constitutional member when the strength of the sealing
material 150 itself is increased.
- (3) With each of the examples noted above, the ink supply port 122 is arranged with
an offset in relation to the ink lead-out unit 131, but the ink lead-out unit 131
and the ink supply port 122 can also be arranged on roughly the same line. It is acceptable
as long as there is an optimal arrangement structure that is suitable according to
the internal flow path structure of the ink flow sensor 140.
- (4) With each of the examples noted above, when filling ink, the ink supply pump PP
was used, but instead of this, it is also possible to execute the ink filling process
using the water head difference which is the height difference of the ink cartridge
110 and the ink reservoir tank 1200. In this case, it is possible to execute ink filling
without using a power source.
- (5) With each of the examples noted above, during ink filling, pressurized filling
is executed using the ink supply pump PP, but it is also possible to fill ink using
vacuum suction using a suction pump such as a vacuum pump or the like. In this case,
it is possible to smoothly execute ink filling.
- (6) With each of the examples and embodiments noted above, we described examples with
ink as the liquid, but instead of this, it is also possible to apply this to a liquid
container for housing drinking water.
- (7) With each of the examples and embodiments noted above, the sealing material 150
is not limited to being a film shaped material, but can also be a somewhat thin plate
material having flexibility. Also, as the sealing material 150, when a material different
from that of the case 120 is used, it is acceptable as long as the same material as
the case 120 is arranged at the contact surface with the wall surface 120c at least
at the sealing material 150.